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Old 06-26-2014, 09:08 AM   #11 (permalink)
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Looking great!

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Old 06-26-2014, 01:10 PM   #12 (permalink)
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The 2x4s on the outside of the box... why not just "skin" the sides with a sheet of coro over the members like you did on the bottom. It should be easy, just staple gun it on the outside.
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Old 06-26-2014, 01:20 PM   #13 (permalink)
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Originally Posted by samwichse View Post
The 2x4s on the outside of the box... why not just "skin" the sides with a sheet of coro over the members like you did on the bottom. It should be easy, just staple gun it on the outside.


I'm actually planning to make each one a little more aero. I already have a 3/4 chamfer on the front of the 2x4 w/ some belt sanding. Next up is to cut some sheets of foam out for the tail end, then use the belt sander to give it the last bit of shape. I think this should be the most effective way to go.
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Old 06-26-2014, 01:44 PM   #14 (permalink)
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4x8 sheets of 1/2" foam board can be used anywhere structural integrity is not needed. They can be bent and or twisted into nearly any shape desired. Complex, compound curves are possible. Your same belt sander can be used to feather the edges of the foam if needed. You can glue, tape or screw it down with fender washers.

Keep up the good work...

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Old 06-26-2014, 03:18 PM   #15 (permalink)
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I agree that the external stakes are an opportunity. Add ribs top and bottom. The top one can be a 3-4" radius (since you've already cut the top piece) that tapers to 0 at the ends, max width 70% of the way between the stakes. The beveling helps.

Fenders? Get a surfboard off Craigslist and cut it in half:
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Old 06-26-2014, 05:02 PM   #16 (permalink)
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You could skin the sides and even flex the lower portion out over the fenders making a nice skirt/wheel faring that is basically a nice smooth side.
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Old 06-30-2014, 09:36 AM   #17 (permalink)
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Alright, got some work done...





I got a chance to pull it with a good heavy load this weekend. Going into EOC, it was much smoother than prior. I could glide just about as good as if the trailer weren't there! I still have some testing to do, but so far, my car seems to appreciate my efforts.
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Old 06-30-2014, 09:47 AM   #18 (permalink)
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Looking good...

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Old 06-30-2014, 01:45 PM   #19 (permalink)
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It looks sufficiently stout. Were the joints glued as well as screwed?

Tell us about the gray twisted thing. Bungee? Taillight wiring? And the holes between license plate and taillights. Rear view cameras?
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Old 07-01-2014, 09:28 AM   #20 (permalink)
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It looks sufficiently stout. Were the joints glued as well as screwed?

Tell us about the gray twisted thing. Bungee? Taillight wiring? And the holes between license plate and taillights. Rear view cameras?
Glued and screwed. Some got the nailer because of tough angles. Clamping where possible.

Bungee, yes. I wanted to have a bit more support on the rear pulling it up. Bungees were too long, so I twisted them up to give them a bit more tension. I've swapped this out for shorter bungees now.

Tail light wiring was pretty easy. Used 18 gauge speaker wire as these lights pulled little power (LED). I used a trailer 4 pin connector at the tail to rear gate to make the tail able to come off easily. There are also license plate lights on there. Wasn't sure if it was required legally, but was cheap enough, so went with it.

The holes on the rear were in case any air made its way inside the tail. It would be a parachute if so! I don't have it completed yet, so I know it's not as sealed up as needed. So I figured it wouldn't hurt to give the air somewhere to go if it did get trapped in there. Plus... weight reduction? lol.

Backup camera... hmmmmm... I do have one laying around. Might have to consider this option! lol.

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